Contacting Module for a Transmission Controller, Transmission Control Module, and Method for the Production Thereof

ABSTRACT

The invention relates to a contacting module for a transmission controller, comprising: a module housing ( 3, 5 ), and a punched grid ( 4 ) made of metal, which is accommodated in the module housing ( 3, 5 ) and has several conducting tracks ( 4   a ) having free ends ( 4   b ), wherein contact surfaces ( 12 ) for contacting are formed at the free ends ( 4   b ). According to the invention, free spaces ( 10 ) are formed in the module housing ( 3, 5 ), said free spaces extending through the module housing ( 3, 5 ) in a vertical direction (v), at least some of the free ends ( 4   b ) are arranged at least partially in the free spaces ( 10 ), the contact surfaces ( 12 ) of at least some of the free ends ( 4   b ) extend substantially in the vertical direction (v), and at least some of the free ends ( 4   b ) are elastically yielding at least in the area of the contact surfaces ( 12 ) thereof.

The present invention generally relates to embodiments of a contacting module for a transmission controller, which module serves to make contact with solenoid valves and an electronic control unit, preferably also sensors. Furthermore, the present invention relates to a method for producing such a contacting module, to a transmission control module having such a contacting module, as well as to a method for manufacturing the transmission control module.

Contacting modules of the general type under consideration serve as parts of transmission controllers for performing various complex contacting operations. In this context, the electronic control unit is placed in contact with the respective solenoid valves that are to be actuated, and in general with sensors, for example acceleration sensors, rotational speed sensors, pressure sensors.

The contacting modules are embodied in general with a plastic housing and a line carrier, which is in turn embodied as a flex film or punched grill. Flex films are generally soldered or welded. Contact is conventionally made with punched grills by means of plug-type contacts.

However, contacting devices of this type are generally not without their problems. Soldered connections are inclined to slip under or fail in the case of mechanical loading, in particular mechanical micro-movements. Plug-type connections are subject to wear in the case of mechanical micro-movements, with the result that an oxide layer can form and the ohmic resistance of the contacting device rises, with the result that, under certain circumstances, sensor signals can be influenced and falsified, and, under certain circumstances, undesired contact interruptions can occur.

It is therefore an object of the present invention to provide a contacting module, and a transmission control module with such a contacting module, which can be produced at relatively low cost and nevertheless permit contact to be made securely even in the case of relatively high or relatively complex mechanical loading.

This object can be achieved by means of a contacting module as claimed in claim 1 and a transmission control module as claimed in claim 12, and further by methods for producing the contacting module according to the invention and the transmission control module. The dependent claims describe additional features.

According to embodiments of the present invention, free spaces that run in the vertical direction and in which the free ends of the punched grill or at least some of the free ends of the punched grill are accommodated are formed in the module housing. The free ends can project outwardly from the module housing, in particular, in the vertical direction, i.e. upwardly or downwardly, in order to make contact with corresponding contact tongues of the relevant components, i.e. the solenoid valves and, if appropriate, sensors. In this context, the contacting module can, for example, be fitted onto the control housing with the pre-mounted components. As a result, the contact tongues of the components pass through the vertical free spaces and remain spaced apart somewhat in the lateral direction with respect to the contact surfaces of the free ends of the punched grill. Also, contact tongues of the components and the free ends of the punched grill can subsequently be compressed, for example by a resistance welding device, and placed in contact with one another.

According to embodiments of the present invention, the free ends are elastically resilient to such an extent that they can be easily placed in contact with the contact tongues. Furthermore, in the case of the movements that occur, in particular the micro-movements, they are elastically resilient and therefore absorb the movements, with the result that the contacting devices, i.e. for example the welded connections, are not loaded. In this context in particular, there may be provision for the free ends to be contoured with a bent and/or curved profile of the conductor tracks.

The housing can advantageously be embodied as two shells with an upper shell and a lower shell latched to one another. For example, the shells can be clipped to one another, or welded, caulked, stamped or riveted, as appropriate. In this context, the two shells are also held together by the attachment of the housing to the control housing and the components by means of corresponding screws or the like. With a two-shell construction of this type, the punched grill can firstly be placed in one of the shells, for example the upper shell, and secured, for example, by means of stamping, and subsequently the other shell can be fitted on, wherein the free ends are accommodated in the free spaces and advantageously project upwardly. The contacting module, which is formed cost-effectively and quickly, subsequently permits secure contact to be made in a way that withstands the mechanical loading that occurs, in particular also micro-movements. For this purpose, a welding device can successively move the contact-forming parties in the free spaces or above the free spaces and make contact between them.

The present invention will be explained in greater detail below on the basis of an exemplary embodiment and with reference to the appended drawings, in which:

FIG. 1 shows a contacting module according to an embodiment of the present invention attached to a control housing;

FIG. 2 is an exploded view of the contacting module;

FIGS. 3 and 4 show the contacting module with the free ends of the punched grill and free spaces of the module housing, respectively, providing an inner view of the module housing;

FIG. 5 is a side view of the module housing in the region of a free end of the punched grill; and

FIG. 6 shows the transmission control module according to an embodiment of the present invention in the region in which contact is made with a free end of the punched grill.

A contacting module 1 according to an exemplary embodiment of the present invention is shown in FIG. 2 in an exploded illustration and is attachable to a control housing 2, as depicted in FIG. 1. The contacting module 1 has, according to FIG. 2, a lower shell 3, a punched grill 4 and an upper shell 5. Shells 3, 5 can each be embodied as plastic parts, for example injection molded parts, and latched or clipped to one another, with the result that they securely accommodate the metallic punched grill 4 between them.

The punched grill 4 is produced in a known manner by punching out a piece of sheet metal, for example made of bronze, and has conductor tracks 4 a and free ends 4 b, which serve to make contact and are connected to one another by means of the conductor tracks 4 a. The entire contacting module 1 serves to alternately make contact with the connected components, in particular sensors 7, for example pressure sensors or travel sensors, and solenoid valves 6 as well as a control unit (not shown). The attachment of the fitted-together contacting module 1 to the controller housing 2 is shown in FIG. 1, wherein the contacting module 1 is connected both to the solenoid valves 6 and, if appropriate, sensors 7 as well as to the control housing 2 by means of, for example, screws 8. Furthermore, contact is made intermediately by means of the free ends 4 b of the punched grill 4 with corresponding contact tongues of the components 6, 7, as is described below.

According to the exemplary embodiment of the present invention, free spaces 10 are formed in the two shells 3, 5. The free spaces 10 are aligned with one another and therefore form continuous free spaces 10 in the vertical direction V—which corresponds to the mounting direction. The conductor tracks 4 a of the punched grill 4 run essentially within the horizontal plane, wherein the free ends 4 a are bent, and the contact surfaces 12 of the free ends 4 b are formed in turn in the vertical direction V or, if appropriate, also partially somewhat bent with respect thereto, as is shown in detail with respect to FIGS. 3, 4, 5, 6. In this context, the free ends 4 b are accommodated entirely or mainly in the continuous free spaces 10 and therefore run in the free spaces 10 of the upper shell 5 in the vertical direction and/or also project through. The free ends 4 b have novel contouring, which will be described below.

FIGS. 3 and 4 show internal views of the contacting module 1 and views of the lower side of the upper shell 5 after the punched grill 4 has been inserted and before the connection to the lower shell 3. Stamping pins (e.g., plastic knobs) are formed as securing regions 14 on the underside and/or inner side of the upper shell 5. The securing regions 14 are stamped mechanically during or after the insertion of the punched grill 4, for example according to FIG. 4 in the eyes of the punched grill 4 or according to FIG. 3 on both sides of the conductor tracks 4 a, with the result that after the mechanical stamping or deformation, the punched grill 4 is secured in the upper shell 5. The stamping pins therefore serve as securing regions 14 and are spaced apart from the free ends 4 b, with the result that they can be adjusted flexibly.

The free ends 4 b can, according to the exemplary embodiment of the present invention, be adjusted in an elastically resilient or flexible fashion owing to their contouring, advantageously in all three spatial directions. As a result, the punched grill 4 can compensate tolerances in all the spatial directions through the flexible embedding in the two shells or half-shells 3, 5. Furthermore, as a result of this connection, the transmission of relative movements from the fixedly embedded regions around the securing regions 14 is reduced. Since the punched grill 4 with its conductor tracks 4 a is no longer secured over a large area in the two-shell housing 3, 5, but is instead secured only in the securing regions 14, oscillations induced in the housing 3, 5 are transmitted directly as far as the free ends 4 b to a small degree. The punched grill 4 can therefore be adjusted around the securing regions 14 between the shells 3, 5.

FIGS. 3, 4 and 5 show various contouring possibilities of the free ends 4 b. According to FIG. 4, the conductor track 4 a runs as far as the free space 10 in the upper plate 5 and then makes a 90° downward bend 15 a (upward in FIG. 4) with a first radius, then carries out a 180° upward bend 15 b into the free space 10 and/or through the free space 10 with a relatively small radius, after which, according to FIG. 4, there is a lateral adjoining section 15 c, i.e., one that extends essentially in the horizontal direction, in which, according to FIG. 4, the stamped metallic conductor track of the free end 4 b runs in the vertical direction, i.e., is bent with respect to the horizontal run of the conductor tracks 4 a. The section 15 c makes the subsequent 90°bend 15 d, with the result that the stamped conductor track subsequently runs, for example, horizontally again or somewhat obliquely with respect to the horizontal, with a subsequent opposing bend 15 e that is adjoined by the contact surface 12, which is widened in order to make contact better. The contact surface 12 can, for example, be bent somewhat at its upper region—the lower region in FIG. 4. Also, contact surface 12 can include a welding dimple 17, for example, for subsequent resistance welding.

FIG. 3 shows a further embodiment in which the conductor track 4 a firstly runs, after it is secured in securing regions 14, in the plane of the upper shell 5 with bends, and subsequently extends horizontally as a free end 4 b underneath the free space 10, where two webs 16 run, for example, bent in parallel away from the conductor track 4 a and upwardly with a 90° bend 15 f through the free space 10 of the upper plate 5, wherein the contact surfaces 12 adjoin one another at their upper end. FIG. 5 corresponds to this embodiment.

The free ends 4 b can therefore each be formed by subsequently bending the initially planar punched grill 4. The bending of the free ends 4 b can already take place during the punching process out of the piece of sheet metal as a separate bending process or else during the stamping of the two shells 3, 5.

The contouring of the free ends 4 b therefore permits resilience in the three spatial directions, both during the contacting and also in the case of loading during subsequent operation.

Solenoid valves 6 and sensors 7 are mounted or pre-mounted, partly by means of the screws 8 and/or by means of plug-type contacts, on the control housing 2 shown in FIG. 1. The inventive contacting module 1, which is described above, is subsequently fitted on. According to FIG. 1, the latter is advantageously attached both to the control housing 2 and to the components, i.e., the solenoid valves 6 and the sensor 7 and, for example, in turn by means of screws 8. The screws 8 can therefore serve both for attaching the contacting module 1 both to the control housing 2 and to the components 6, 7. In this context, according to FIG. 1, the contact surfaces 12 of the free ends 4 b project upwardly out of the free spaces 10, wherein during the mounting process the contact tongues 18 according to FIG. 6 pass through the free spaces 10 of the shells 3, 5 and subsequently run parallel to, and somewhat spaced apart from, the contact surfaces 12 of the free ends 4 b. The welding dimple 17 lies on the side of the contact surface 12 that faces the contact tongue of components 6 or 7. FIG. 6 therefore shows the contacting region between the contact surface 12 and the contact tongue 18 for the subsequent materially joined and/or positively locked connection.

In the embodiment shown, contact is made by means of a welded connection, in particular a resistance welded connection. For this purpose, in FIG. 1, a welding device moves the two welding partners 18, 12 from above in the respective free spaces 10, presses the contact tongue 18 and contact surfaces 12, respectively, together and welds them to one another. Alternatively, positively locking connections are also possible by means of corresponding latches; if appropriate, connections can be made by means of a suitable solder, in particular a high temperature solder or else conductive adhesive.

The control unit (ECU) is subsequently fitted onto the contacting module 1 from above, for which purpose it has, for example, a suitable multi-pin connector with which it is fitted onto a plug receptacle 20 formed in the central right-hand region of the contacting module 1. The transmission control module 22 is therefore formed and is subsequently fitted onto the respective transmission.

In FIG. 2, pistons 24 and air inlets 25 and air outlets 26 are provided for pneumatic control in a known manner. 

1. A contacting module for a transmission controller, comprising: a module housing (3, 5); and a punched grill (4) made of metal, the punched grill accommodated in the module housing (3, 5), and having a plurality of conductor tracks (4 a) with free ends (4 b), wherein contact surfaces (12) for making contact are formed at the free ends (4 b); characterized in that free spaces (10), which extend in a vertical direction (v) through the module housing (3, 5), are formed in the module housing (3, 5); at least some of the free ends (4 b) are arranged at least partially in the free spaces (10); the contact surfaces (12) of at least some of the free ends (4 b) run essentially in the vertical direction (v); and at least some of the free ends (4 b) are of elastically resilient design, at least in the region of their contact surfaces (12).
 2. The contacting module as claimed in claim 1, characterized in that the free ends (4 b) project out of the housing (3, 5) in the vertical direction (V) at least in the region of the contact surfaces (12) of said free ends (4 b).
 3. The contacting module as claimed in claim 1 or 2, characterized in that at least some of the free ends (4 b) have a multiply curved profile (15 a, b, c, d).
 4. The contacting module as claimed in one of the preceding claims, characterized in that at least some of the free ends (4 b) have, in their respective free spaces (10), a bend in the vertical direction (v) out of the horizontal plane of the punched grill (4).
 5. The contacting module as claimed in claim 4, characterized in that at least some of the free ends (4 b) are formed entirely or partially by bends and/or curved profiles of the respective conductor tracks (4 a) with a widened formation in their contact surfaces (12).
 6. The contacting module as claimed in one of the preceding claims, characterized in that at least some of the free ends (4 b) have parallel webs (16) which protrude from the respective conductor track (4 a) and are curved and/or bent.
 7. The contacting module as claimed in one of claims 4 to 6, characterized in that the punched grill (4) is bent only at the free ends (4 b) and is otherwise of planar design.
 8. The contacting module as claimed in one of the preceding claims, characterized in that the housing (3, 5) has an upper shell (5) and a lower shell (3) connected to one another, for example latched and/or welded, and the punched grill (4) is accommodated between the two shells (3, 5), wherein vertical free spaces (10) are formed in the two shells (3, 5) which are aligned with one another.
 9. The contacting module as claimed in claim 8, characterized in that the punched grill (4) is mechanically secured to at least one of the two shells (3, 5) in regions (14) by means of mechanical stamped elements, for example projecting stamped pins (14).
 10. The contacting module as claimed in claim 9, characterized in that the punched grill (4) is accommodated in the region of its free ends (4 b) without an attachment and as a result is elastically adjustable between the shells (3, 5) in the horizontal plane.
 11. The contacting module as claimed in one of the preceding claims, characterized in that the free ends (4 b) are elastically adjustable in three dimensions at least in the region of their contact surfaces (12).
 12. A transmission control module (22) for a vehicle transmission, wherein the transmission control module (22) has at least: a contacting module (1) as claimed in one of the preceding claims; a control housing (2) in which pneumatic cylinders and pistons (24) and air inlets and air outlets (25, 26) are formed; solenoid valves (6) whose contact tongues (18) are placed in contact with free ends (4 b) of the punched grill (4); at least one sensor (7) which is attached to the control housing (2) and is placed in contact with the punched grill (4); and an electronic control device which is plugged onto the contacting module (1) and placed in contact therewith; wherein the contacting module (1) is attached to the control housing (2).
 13. A method for manufacturing a contacting module as claimed in one of claims 1 to 11, having at least the following steps: forming a punched grill (4) with conductor tracks (4 a) and free ends (4 b), wherein at least some of the free ends (4 b) are bent in the vertical punching direction (v), inserting the punched grill (4) into a shell (3, 5), and mechanically securing it by stamping the shell (3, 5); and combining and connecting the shell (3, 5) with a further shell (5, 3) to form a housing in which free spaces (10) which are continuous in the vertical direction (v) are formed, in which free spaces (10) at least some of the free ends (4 b) of the punched grill are arranged.
 14. A method for manufacturing a transmission control module (22) for a vehicle transmission as claimed in claim 12, wherein the contacting module (1) is fitted onto a control housing (2) with pre-mounted solenoid valves and at least one sensor (7) such that contact tongues (18) of the solenoid valves and/or of the sensor (7) project jointly with free ends (4 b) of the punched grill (4) through free spaces (10) of the contacting module (1), and the free ends (4 b) and the contact tongues (18) are subsequently compressed and welded to one another, preferably by means of a resistance welding device. 